Method of and apparatus for making patterned tufted pile fabric



J. L. CARD Jan. 3, 1961 METHOD OF AND APPARATUS FOR MAKING PATTERNEDTUFTED FILE FABRIC Original Filed Dec. 24., 1952 v 9 Sheets- Sheet 1VENTOR law/a KJ/a III-III III I IIIII" ATTORNEY J. L. CARD Jan. 3, 1961METHOD OF AND APPARATUS FOR MAKING PATTERNED TUFTED PILE FABRIC-Original Filed Dec. 24, 1952 9 Sheets-Sheet 2 INVENTOR fla [e M5 am 3Y2Z 5 E l ATTORNEY Jan. 3, 1961 J. L. CARD 2,966,866

METHOD OF AND APPARATUS FOR MAKING PATTERNED TUFTED FILE FABRIC OriginalFiled Dec. 24. 1952 9 Sheets-Sheet 3 l INVENT OR fse n- [e WAS ("67/ BYm J. L. CARD Jan. 3, 1961 METHOD OF AND APPARATUS FOR MAKING PATTERNEDTUFTED PILE FABRIC 9 Sheets-Sheet 4 Original Filed Dec. 24, 1952 a w WINVENTOR Jase 0r; [aw/6 Ca/"Q Jan. 3, 1961 J. L. CARD 2,966,865

METHOD OF AND APPARATUS FOR MAKING PATTERNED TUFTED PILE FABRIC OriginalFiled Dec. 24, 1952 9 Sheets-Sheet 5 INVENT OR %4 W-mmw J. L. CARD Jan.3, 1961 METHOD OF AND APPARATUS FOR MAKING PATTERNED TUFTED FILE FABRIC9 Sheets-SheetB Original Filed Dec. 24. 1952 1N VENTOR fiaep [8 MI? aw'oATTORNEY Jan. 3, 1961 J. 1.. CARD ,8

METHOD OF AND APPARATUS FOR MAKING PATTERNED TUFTED PILE FABRIC OriginalFiled Dec. 24, 1952 9 Sheets-Sheet '7 5:5 &-

H I l INVENTOR JZsep/y [eh/A's Crol BYZ z a b I a ATTORNEY Jan. 3, 1961J. CARD 2,966,866

METHOD OF AND APPARATUS FOR MAKING PATTERNED TUFTED FILE FABRIC OriginalFiled Dec. 24. 1952 9 Sheef os-Sheet 8 INVENTOR flee a6 Jew/5 fire l-i-w ATTORNEY Jan. 3, 1961 J 2,966,866

METHOD OF AND APPARATUS FOR MAKING PATTERNED TUFTED PILE FABRIC OriginalFiled Dec. 24, 1952 9 Sheets-Sheet 9 T55 .LE

INVEN TOR fisep/z [e M/l5 65/"0 ATTORNEY METHOD OF AND APPARATUS FORMAKING PATTERNED TUFTED PILE FABRIC Joseph Lewis Card, Chattanooga,Tenn., assignor, by mesne assignments, to Cobble Brothers MachineryCompany, Inc.

Continuation of application Ser. No. 327,807, Dec. 24, 1952. Thisapplication Mar. 26, 1959, Ser. No. 802,262

Claims. (Cl. 112-79) This invention relates generally to a method of andapparatus for making a tufted pile fabric having pile loops of differentlengths in selected areas thereof.

The principal object of the invention is to provide a method of andmeans for positively feeding and controlling yarn supplied to tuftingmachines in a manner such that selected areas of the tufted fabric mayhave pile loops of different lengths and to select such areas in amanner to provide predetermined design features or patterns in thefinished fabric.

Another object of the invention is to provide a positive yarn or threadfeed adapted for use on tufting machines of conventional design,together with means for operating the yarn feed mechanism at differentspeeds in respect to the frequency of operation of the needle mechanismof the tufting machine in order positively to deliver to the needlemechanism, when desired, different predetermined lengths of yarn orthread for each excursion of the needle, thereby to vary the length ofthe pile loop formed by the needle.

A further object of the invention is to provide a positive yarn orthread feed for a tufting machine which will deliver yarn to the needleor needles of the machine at selected rates calculated to providepredetermined different lengths of yarn to the needle for each excursionthereof while maintaining a uniform depth of penetration of the basefabric by the needle, so that when thread increments of less than themaximum length are being fed to the needle, yarn or thread included in apreviously formed loop is pulled back by the needle mechanism to make onthe last stitch being formed a loop of maximum length.

Another object of the invention is to provide a positive thread or yarnfeed of the type here referred to which may be adapted to multipleneedle machines, together with a pattern control mechanism forautomatically controlling the amount of thread or yarn feed to differentselected groups of needles, thereby to define in the fabric being formeda pattern comprising contiguous contrasting areas of long and shortloops or high and low pile.

Another object of the invention is to provide positive yarn or threadfeed mechanism comprising positively driven feed rollers which draw thethread or yarn from a suitable thread supply and feed the same to theneedles of the machine at different rates of feed under the control ofpattern mechanism in a manner such that when less than the maximumincrement of thread or yarn is being supplied to the needles, theneedles will form loops of maximum length made jointly from threadsupplied thereto by the feed rolls and from thread pulled back frompreviously formed loops, thereby successively to reduce the height orlength of said previously formed loops.

Another object of the invention is to vary the length of the incrementsof thread or yarn fed to the needles by varying the speed of the feedrolls automatically under the control of a pattern control mechanism.

Another object of the invention is to provide a yarn 2,965,856 PatentedJan. 3, 1961 feed of yarn or thread to the needles while maintainingsaid uniform depth of penetration of the fabric by the needles.

These and other objects of the invention will become apparent from aconsideration of the following specification read in the light of theaccompanying drawings,

wherein a preferred embodiment of the invention has been illustrated,while the salient features of the invention are pointed out moreparticularly in the appended claims.

In the accompanying drawings,

Fig. 1 is a top plan view of the tufting machine with the presentinvention attached thereto,

Fig. 2 is an end elevation of the lefthand end of the machine as viewedfrom the front of the machine,

Fig. 3 is an end elevation of the opposite end of the machine,

Fig. 4 is a vertical, sectional view taken on the line 4-4 of Fig. 1,

Fig. 5 is a front elevation of the lefthand end of the machine showingthe variable speed drive means for the feed rollers, with the cover forsaid drive means housing removed,

Fig. 6 is a vertical, sectional view taken on the line 66 of Fig. 5,showing the housing cover open, with parts thereof broken away,

Fig. 7 is a vertical, sectional view taken on the line 77 of Fig. 5,showing the housing cover closed and the panel box for the electriccontrol mechanism mounted thereon,

Fig. 8 is a vertical, sectional view of the pattern control mechanismmounted on the rear portion at the right hand end of the machine, withthe microswitches and supporting bracket removed,

Fig. 9 is a diagrammatic view of the manner in which the full lengthpile loops are formed,

Fig. 10 is a diagrammatic view showing the manner in which the pileloops of reduced length are formed,

Fig. 11 is a fragmentary view showing one pattern design which may beexecuted on a machine equipped with the yarn feed of the presentinvention,

Fig. 12 is a top plan view of a piece of fabric showing another patterndesign which may be executed on a machine equipped with the yarn feed ofthe present invention, and

Fig. 13 is a diagrammatic view of the electrical control system by whichthe speed change mechanism for the feed rolls may be actuated.

Referring more particularly to the accompanying drawings, wherein likereferrence numerals designate like parts throughout, the invention isshown operatively associated with a multiple needle tufting machine ofconventional design. The tufting machine comprises a framework includingend legs 1, center legs 2, top housing 3, and bed plate 4. The tophousing 3 is generally hollow, as shown more particularly in Fig. 4, toform a a motor-driven pulley 9, which pulley is driven by an electricmotor 10 suitably supported on the said leg 1 as shown in Figs. 2 and 5.The shaft 5 intermediate its ends is provided with a plurality ofeccentrics 11 with which are operatively associated links or pitmans 12.The links 12 are connected at their lower extremities to verticallyreciprocable rods 13 which are suitably guided for vertical movement inguide bearings 14- carried by the housing 3, as clearly shown in Fig. 4.The rods 13 are attached at their lower extremity to the needle bar 15,said bar carrying a plurality of needles The needles may be securedwithin the bar 15 by any suitable means such as set screws 17 shown inFig. 5. The needles 16 are arranged to reciprocate through an aperturedneedle plate 18 carried by the bed plate 4 and at the upper limit oftheir excursion are clear of said needle plate.

The tufting machine includes a hook member for each needle 16, and saidhook members are shown in Fig. 4 at 19. They are mounted on a rock shaft23 suitably mounted within the bed plate 4 for rocking movement in timedrelation to the reciprocation of the needles with which they areoperatively associated, in a conventional manner. No means are shown forrocking the hook members 19, but they are rocked back and forth aboutthe axis of the shaft 29 to engage and disengage the thread loops whichare projected through the needle plate 18 by the needles 16 in a wellknown manner. The shaft 26 may be rocked by a conventional link and armmechanism driven by the needle shaft 5 in a known manner, such forinstance as is shown in the patent to McCutchen 2,423,608. It will beunderstood that the operation of the shaft 23 and the hook members 19 issuch that as a needle 16 carrying a thread loop reaches the lowermostportion of its downward excursion, the hook 19 will be rockedcounterclockwise in Fig. 4 to engage the hook with the loop to retainthe loop in its projected position during the retraction of the needleupwardly through the needle plate and base fabric. The hook members 19are then withdrawn from the respective loops by a rocking movement in aclockwise direction, and this action is repeated for each stitch of theassociated needle. All of this is conventional in what are known assingle hook tufting machines, and the mechanism for so actuating thehooks forms no part of the present invention.

As is conventional in forming tufted pile fabric on a sewing machine, abase fabric such as 21 is fed across the needle plate 18 from a suitablesupply roll 22 by feed rolls 23 at the front of the machine and feedrolls 24 at the rear of the machine. The feed rolls 23 and 24 may bedriven by a chain of gearing which includes the belt member 25 drivenfrom the shaft 5, said belt driving a pulley 26 connected to a stubshaft 27 which, through appropriate gearing within the gear box 28drives the shaft 29 on which the rear feed roll 24 is mounted. Theopposite end of the shaft 29 carries a sprocket gear 30 which drives, bymeans of sprocket chain 31, the shaft 32 at the front of the machine onwhich one of the front feed rolls 23 is mounted.

The tufting machine as thus far described is quite conventional and inits normal operation, when yarn or thread is supplied to the needles 16,will project pile loops of uniform height or length through the basefabric 21 to form a tufted pile fabric of conventional type and in whichthe pile is of uniform depth. Machines of this type are well known andare made in several different sizes, depending upon the length of theneedle bar and the number of needles carried thereby. They arecharacterized by the fact that the needles operate in unison and to auniform depth of penetration with respect to the base fabric, andprovide a product in which the pile loops are of uniform length.

Machines are known in which provision is made for the formation of pileloops of different lengths by the adjustment of the height of the hookmembers with respect to the bed plate, but these devices are complicatedand unsatisfactory and used only on specialized machines.

As previously stated, it is an object of the present invention toprovide a method of and means for regulating the supply of thread oryarn to a tufting machine of conventional character in a manner suchthat patterned loop pile fabric may be made wherein the contrastingareas of the resulting pattern are defined by pile loops which are ofdifferent lengths or heights. To this end, the invention contemplatesthe provision of means for positively feeding yarn to the needles 16 andmore particularly for varying the rate of feed of' the yarn or thread.The positive yarn feed of the present invention comprises a plurality ofpairs, of rolls which are shown more particularly in Figs. 1 and 4 andare there indicated by the reference characters 33, 33, 34, 34', 35,35', 36 and 36. Although I have chosen to show the yarn feed means ineach instance as a pair of feed rolls, it is to be understood that asingle feed roll having a drawing or anti-slip surface may be employedin lieu thereof'if desired. The pairs of feed rolls as shown are mountedgenerally horizontally of the machine and above and in front of thehollow top housing 3. Each pair of rollers shown in the preferredarrangement comprises a power driven roller and a cooperating roll whichis intergeared respectively with the power driven roll. The power drivenrolls carry the numerals 33, 34, 35, and 36, while the intergeared rollscarry the same reference numerals with a prime. The righthand end ofeach roller as viewed in Fig. 1 is mounted in a suitable mountingbracket 37, and this bracket also carries (not shown) the gear membersby which the respective rolls of each pair are interconnected. Theopposite ends of the intergeared rollers 33', 34, 35, and 36 are mountedfor rotation upon the righthand side or end wall 38 of the housing 39within which is disposed a change speed mechanism for the driven rolls33, 34, 35 and 36. To this end, the driven roll shafts extend throughthe end wall 38 of the housing 39 and terminate in suitable bearings 40carried by the opposite end wall 41 of the housing 39. The respectiveroll shafts within the housing 39 are each provided with a pair ofclutch members C and C The clutches C and C for each of the roll shafts33, 34, 35 and 36 are identical, so only one of the pairs of clutches Cand C will be described in detail. The clutches C and C may desirably bemagnetically actuated clutches, although any other form of actuationmaybe employed if desired. The clutches themselves form no part of theinvention, but are conventionally constructed clutches which are boughton the open market, and each includes two parts, one of whichis fixed tothe respective shaft and one of which turns, freely on the shaft. InFig. 5, referring to the clutches C and C associated with the roll shaft33, the lefthand half of the clutch C is fixed to the shaft 33 while therighthand half thereof is free to rotate on the roll shaft 33 and isdriven by a sprocket chain 42. In respect to clutch C for roll shaft 33,the right hand half of this clutch is fixed to the roll shaft and thelefthand end is free to rotate on the shaft and is driven by thesprocket chain 43. The sprocket chains 42 and 43 as shown in Figs. 6 and7 are operatively associated with the respective clutches by sprocketsof different diameter, the sprocket chain 42 driving a sprocket 44 oflarge diameter carried by the loose half of clutch C and the sprocketchain 43 driving a sprocket 45 of smaller diameter carried by the loosehalf of clutch C The sprocket chains 42 and 43 are driven from acountershaft 46 housed within the lower part of the housing 39 with theleft hand end of said shaft extending through the end wall 41, and thereprovided with a sprocket 47 which. is

driven by a sprocket chain 48 from a stub shaft 49which in, turn isbelt-connected to the shaft 5. by a belt; 50.

Thus, the countershaft 46 is driven from the needle shaft 5 by the motor10. The countershaft 46 carries eight sprocket wheels 51, preferably allof the same size and two of which drive the Sprocket chains 42 and 43for the free halves of the respective clutches C and C for roll shaft33. The drive means just described for roll shaft 33 is duplicated foreach of the roll shafts 34,

35 and 36. Thus, it is apparent that the countershaft' 46 functions toimpart to the clutches C and C of eachv roll shaft, either one of twodifferent speeds of operation selectively, depending upon which of theclutches C and C thereof is energized by means of the magnetic actuatorassociated with each of said clutches. The magnetic actuator for eachclutch is housed within that half of,

the clutch which is splined or fixed to the respective roll shafts, andelectric current for energizing the respective clutches is deliveredthereto through brushes 52 operating upon conventional slip rings 52a.The brushes are supported in operative relation in respect to theseveral clutch parts by brackets 53 carried by the housing 39. Althoughonly two clutches, C C are shown for each feed roll shaft, it is ofcourse possible to provide three or 1 more such clutches for each shaft,each clutch being arranged to drive the associated shaft at a differentspeed. By so doing, more intricate patterns may be developed in thefinished fabric, since by this means, it is possible to provide pileloops of three or more different lengths, depending upon the differentspeeds provided by the several clutches. Also, it is contemplated, ifdesired, to provide means to vary the speed of the shaft 46, as byincluding a changeable gear or sprocket in the drive between the shafts49 and 46, while maintaining proper direction of rotation of shaft 46.By thus changing the speed of shaft 46, the high or low speeds of theroll shafts may he stepped up or down while maintaining substantiallythe same speed difference between high and low speeds, as reflected inthe difference between high and low" pile loops.

As described in connection with the speed change mechanism associatedwith the several roll shafts 33, 34, 35, and 36, the respective clutchmembers C and C are arranged selectively to drive the associated rollshafts at different speeds, either fast or slow, depending upon theheight or length of the pile loop it is desired to form in the basefabric 21. Thus, the invention contemplates selectively andautomatically energizing the respective i clutches so that selectedareas in the finished fabric may have either long or short pile loopsand the areas so oriented as to define a particular or predeterminedpattern. Accordingly, pattern control mechanism is provided forselectively energizing the respective clutches. The pattern controlmechanism is shown mounted on the rear portion of the right end of thetop housing 3 of the machine as shown more particularly in Fig.1 and ingreater detail in Figs. 3, 4 and 8. The pattern control mechanismcomprises a series of sprocket chains 54 trained over sprocket wheels 55and 56, mounted, respectively, on sprocket wheel shafts 57 and 58. Theshafts 57 and 58 are mounted in suitable brackets 59 and 60 on the rearportion of the top housing 3, and the shaft 58 is driven by a sprocketchain 61 trained over sprockets 62 and 63 carried by the shafts 58 and29, respectively, so that the sprocket chains 54 are driven in unison bythe shaft 29 which is an active part of the base fabric feed mechanism.The sprocket chains 54 function as pattern control means for energizingand deenergizing the clutch members C C and to this end said chainscarry switch operating means in the form of lugs 64. The number andposition of the lugs 64 on chains 54 determine the times when and theinterval during which the clutches C or C are energized, and theparchain being driven from shaft 58 to operate concurrently with patternchains 54. The pattern chain 65 is appreciably longer than the chains54, and as will appear hereinafter, functions to control the end bordersfor the fabric piece being tufted, and for this reason must be as longas the tufted fabric. The smaller pattern chains 54 need only be of alength to produce a single portrayal or execution of the basic patterndesign, which may be repeated as many times as is desired to completethe intended product. The pattern chains 54 and 65 may be varied inlength as necessary to accommodate a particular pattern and/or aparticular piece of fabric being made, and in order properly to positionthe sprocket shaft 57 with respect to the shaft 58, the supporting frame59 may be adjustably mounted on an upstanding slotted arm or bracket 66by means of bolts 67 or any other suitable means. Similarly, theadjustment of the length of the sprocket chain 65 may be accomplished byshifting the sprocket wheel 68 longitudinally of the arm 66 and securingit in adjusted position by a bolt 69. The pattern chain 65 carriesswitch operating lugs 70 similar to the lugs 64 of the pattern chains54.

The control switches to be actuated by the pattern chains selectively toenergize the clutches C C and thus produce a given pattern in thefinished fabric are in the form of conventional microswitches indicatedat 71 and are supported by suitable bracket means 72 in position to beactuated by the respective pattern lugs 64 and 70 as the pattern chainsmove in response to rotation of the sprocket shaft 58. The arrangementof the microswitches is best seen in Figs. 3 and 4, wherein each switchincludes an operating plunger or pin 73 and an overhanging pivoted arm'74. The arms 74 each carry a roller 75 at the free end thereof, andthese rollers are positioned normally to lie in the path of the slugs 64and 70. The arrangement is such that when a portion of the chain whichcarries no lug is aligned with a roller 75, the pin 73 associated withsaid roller arm 74 is projected from the switch casing 71, but when aportion of the chain carrying a lug or lugs passes the roller 75, therelationship is such that the the associated arm 74 is rocked by saidlugs in a clockwise direction as viewed in Fig. 4 to depress the plungerand actuate the switch. The microswitches are conventional inconstruction and may be normally biased either to open or to closedposition as desired, but it will appear from what follows that in thepresent instance the microswitches 71 are biased to a normally openposition.

It should be understood at this point that there are provided as manypattern chains 54 as there are pairs of feed rollers 33, 34, 35 and 36.Obviously, the number of pattern chains and the corresponding number offeed rolls may be varied as desired, depending upon the variety inpattern delineations required. In the present instance, there has beenproposed four pairs of feed rolls together with a like number of patternchains, but this number may be varied up or down as desired, having inmind the extent and complexity of pattern variations desired. It willalso be understood that depending upon pattern requirements, the needlesof the machine may be divided into several groups and that more than onegroup of needles may be called upon to make either long or short loopsat the same time, in which event all needle groups operating to makepattern delineations of a long pile loop are fed from the same set offeed rolls, or from feed roll sets operating at the same speed, and thatall needle groups operating to make short pile loops are fed fromanother set or sets of rolls operating at a common but different speed.

The pattern chains 54 and 65 and the lugs 64 and 70 carried thereby,respectively, selectively actuate the microswitches 71 to energize theclutch members C C of the feed roll shafts 33, 34, 35 and 36. Thus, theseveral feed corresponding to the position and number of the patternlugs 64 and 76 carried by the chains 54 and 65. In Fig. 13, there isshown a diagram of electrical connections representing the circuitconnection between the rnicroswitches, relays controlled thereby, andthe magnetically actuated clutches C C Referring briefly to Fig. 13, theclutches C C are controlled by relays CR CR CR and CR there being onerelay for the pair of clutches C C of each feed roll shaft. Therelays'CR CR CR and CR are each provided with two contacts, one of whichis normally closed and one of which is normally open, as shown. Thenormally closed contacts CRCE, CRC2, CRC3 and CRC4 energize in eachinstance the clutch C 'which is the low speed clutch in the presentinstance, inasmuch as the sprocket 44 is of larger diameter than thesprocket 45 associated with the clutch C The high speed clutch C in eachinstance is controlled by the normally opencontaot of the associatedrelay indicated by CROll, CROZ, CRO3, and CROQ. The microswitches 'iiare shown in Fig. 13 as normally open. The network as shown in Fig. 13is energized from any commercial source of electric current connectedacross terminals T T and by which the transformer Tr is energized. Themicroswitch '71 positioned to be actuated by lugs 7% on the chain 65controls the master relay MR which, as shown in the diagram, is afour-pole relay, the four contacts of which are designated MRCIl, MRC2,MRC3, MRC4 on the diagram. These are normally open contacts, and whenthe associated microswitch 71 energizes master relay MR, the fourcontacts MRCI, MRCZ, MRCE, and MRC4 are closed to energizesimultaneously the four clutch relays CR CR CR and CR the master relaycontacts as shown bypassing the microswitches associated, respective-1y,with the clutch relays. Thus, the function of the long pattern chain 65is apparent in that it functions to control jointly all of the relays toprovide a proper end border for the fabric or rug being made the tuftingmachine. As further shown in the diagram, the network includes the fuseF, a rectifier R, and condensers shunted across the clutch coils in apurely conventional manner. The various relays, transformer, andcondensers disclosed diagrammatically in Fig. 13 may be mounted in anyconvenient manner, such as on a panel P shown in Fig. 7 and housedwithin the box 0, which in turn may be conveniently mounted upon thecover 81 of the housing 39. It will be understood that the electricalelements included in the network shown in Fig. 13 are per se purelyconventional in character and form no part of the present invention.Furthermore, the panel or other mounting means for the controlinstrumentalities included in said network may be placed at anyconvenient location and need not be mounted upon the cover 80 of thehousing 359.

From the foregoing, it is apparent that when energized in response toactuation of one or more of the microswitches 73, the driving mechanismfor the several sets of feed rollers operates at high speed under theinfluence of clutches C and thus yarn is fed to the needles of themachine at a rate sufficient to supply the full demands of the machinewhile making loops of maximum length, that is, loops corresponding inlength to the depth of penetration of the base fabric 21 by the needles15, plus the length of the backstitch between successive loops. Thisoperation is shown diagrammatically in Fig 9 where the pile loops L Lare of a uniform length and the amount of yard fed to a given needlemaking the loops here represented amounts to twice te depth or length ofthe loop plus the length s which represents the backstitch between eachloop.

Fig. 10 shows diagrammatically the operation of the needle and theformation of a loop when thread or yarn is being fed to the needle by aset of feed rolls that is operating at low speed, that is, with itsassociated clutch C energized and the clutch C de-energized. Under thesecircumstances, the feed rolls will supply to the associated needle alesser amount of yarn than is fed under high speed operation, the lengthof yarn per stitch under low speed operation being equal to twice thelength of a given loop L plus the length of the same backstitch s.However, it must be recalled that the needle makes a uniform stroke witha uniform depth of penetration, so that initially, a loop of maximumlength, such as shown in dotted lines at L will be made. However, theincrement of thread supplied to the needle for each cycle of itsoperation under low speed is insufficient to form a loop of maximumdepth such as L so that the needle mechanism will draw froina previouslyformed loop a suflicient amount of thread or yarn to make, with the yarnfed thereto by the feed rolls, a long loop on the hook 19 such as loop Lin Fig. 10. It is believed clear from this explanation that initially,the needle will form a loop of full length such as loops L of Fig. 9 orthe loops L L of Fig. 10, regardless of the speed of operation of thefeed rolls, but in the event the feed rolls are operating at high speedunder the influence of the clutches C the thus-formed loops will remainat full height, as shown in Fig. 9, whereas when the feed rolls areoperating at reduced speed under the influence of clutches C theinitially formed loop of full depth is subsequently shortened a givenamount by the needle mechanism backdrawing thread therefrom, this threadbeing drawn back from the previously formed stitch by the needlemechanism after the thread fed to the needle by the associated feedrolls has been consumed.

The thread or yarn may be drawn back as described, by the needle aloneoperating on its penetrating stroke to pull back thread from apreviously formed loop after all of the slack thread between the feedrollers and the needle has been drawn into the loop being formed. Iprefer, however, to include in the needle mechanism a yarn or threadjerker, as shown at 79 in Fig. 4 to effect the pull back of thread, asdescribed, and this element functions to improve the appearance of theshort nap or pile by making the same even more uniform in height. Theyarn jerker 79 may be in the form of a rod or stiff wire carried by andin front of the needle bar and disposed between the last thread guide 78and the needle 16, the thread being trained over said bar as shown.Thus, the bar 79 moves with the needle bar, and when the feed rollersare operating at low speed, the bar 79 on the withdrawal stroke of theneedle and while the thread or yarn is still engaged with the hook 19,as shown in Fig. 10, will jerk or pull back thread from a previouslyformed loop, and around the hook, having in mind the fact that theengagement of the thread with the feed rolls prevents the thread beingpulled from the thread source beyond said rolls. The thread thus drawnfrom the previously formed loop forms between the thread guide 78 andthe needle sufiicient slack thread to insure the formation of a fulllength loop on the next stroke of the needle. This operation not onlyreduces the length of the previously formed loop a given amount, butalso draws the backstitch s tight across the back of the base fabric.

In Figs. 11 and 12, there are shown examples of the patterned fabricmade on the machine provided with the thread feed constituting thepresent invention, and in each of these figures, the short or low pileareas are represented by L0 and the long or high pile areas arerepresented by Hi. In Fig. 12,- the end border portions EB of the rugare Hi portions and are formed under the control of the master relay MR.Obviously, this relay can be arranged to have these end border portionsof either long or short pile loops, depending upon whether the normallyclosed contacts of the clutch relays CR CR CR and CR energize the highspeed or low speed clutches.

It will be understood that the yarn feed rollers are driven continuouslywhile the machine is in operation, and that only the speed of therollers is changed. Having in mind this continuous thread feed and thereciprocating motion of the needle, it is apparent that thread isconsumed by the needles during each stroke thereof. This operation willcause at times a certain degree of slack in the thread between the feedrollers and the needle bar during each stroke of the needle, and inorder properly to guide and control the thread between the feed rollersand the needle bar, there are provided a plurality of thread guide meansindicated at 76, 77, 78 and 78a as shown in Fig. 4 and through which thethreads from the feed rollers pass to the needles 16.

Any convenient form of thread supply may be provided, but it has beenfound convenient to employ conventional creels (not shown) from whichthe various yarns or threads are drawn by the feed rolls. Obviously,more than one strand of yarn or thread may be handled by each needle tomake a thick pile if desired.

From the foregoing, it is apparent that this invention provides apositive yarn feed mechanism adapted to be interposed between a sourceof yarn supply and a tufting machine and which includes means wherebythe yarn feed may be operated at any one of a plurality of differentrates, so that the machine may, in the manner described, provide tuftedpile fabric with pile loops of different lengths. When the yarn feedmechanism of this invention is applied as described to a multiple needlemachine, the control means includes means for selectively operating aplurality of sets of feed rolls at different speeds in response topattern mechanism, so that a fabric may be made in which adjacent areasthereof are characterized by pile loops of different lengths, thereby toform pattern features of desired definitions.

The invention is capable of being operatively associated with multipleneedle tufting machines of conventional design. or which may be builtinto tufting machines as an integral part thereof.

It is apparent from the foregoing specification, read in the light ofthe accompanying drawings, that various changes may be made in thedesign, arrangement, and size of parts as desfred without departing fromthe spirit of the invention, which is defined more particularly in theappended claims.

This is a continuation of my application Serial No. 327,807, filedDecember 24, 1952, now abandoned, and entitled Method of and Apparatusfor Making Patterned Tufted Pile Fabric.

I claim:

1. In a tufting machine, needle mechanism, a feed roll for continuouslyand positively feeding yarn thereto at different rates, drive means forthe feed roll including a shaft, a plurality of clutch members mountedon said shaft for rotation relative thereto, means for driving eachclutch member at a different predetermined speed, and control meansresponsive to the timed operation of a driven part of the machine forselectively rendering each clutch member active to drive the feed rollat the speed of said clutch.

2. The apparatus described in claim 1 wherein said clutches includemagnetic operating means, and wherein said control means includespattern mechanism driven by said machine, and switch means selectivelyactuated by said pattern mechanism for energizing said magneticoperating means and thereby said clutches in a predetermined sequence.

3. In a tufting machine, needle mechanism, a pair of feed rolls forpositively feeding yarns thereto at different rates, drive means forboth of the feed rolls including a shaft, a plurality of clutchesmounted on said shaft for rotation relative thereto, means for drivingeach clutch member at a different predetermined speed, and control meansresponsive to the timed operation of a driven part of the machine forselectively rendering each clutch member active to drive the associatedfeed roll at the speed of said clutch.

4. A tufting machine comprising a needle bar, a plurality of needlescarried thereby, means for reciprocating the needle bar, a plurality offeed rolls adapted respectively to feed yarn to different predeterminedgroups of the needles, means for driving selectively the respective feedrolls at any one of a plurality of predetermined speeds, said drivingmeans including plural clutches for each feed roll, there being aseparate clutch for each different speed, and control means responsiveto the timed operation of a driven part of the machine for selectivelyenergizing predetermined clutches of any feed roll drive means, therebyto vary the relative driving speed of different feed rolls, magneticoperating means for said clutches, said control means including apattern chain driven by said machine, and switch means selectivelyactuated by said pattern chain and adapted to energize said magneticoperating means and thereby said clutches in a predetermined sequence.

5. A yarn feed mechanism adapted to be interposed between a source ofyarn supply and a multiple needle tufting machine comprising plural yarnfeed rolls each adapted to draw yarn from a yarn supply and deliver thesame to selected groups of needles respectively, means for driving allof said feed rolls at the same speed when desired, said drive meansincluding speed change means for driving any one of said feed rolls at apredetermined different rate of speed, control means for the speedchange means including means operable in timed relation to the machinefor changing the speed of its associated feed roll in accordance withprescribed pattern requirements.

6. The yarn feed mechanism described in claim 5 wherein the drive meansfor each of said feed rolls includes plural clutches together with meansoperatively associated with one clutch for driving the associated feedroll at a rate of speed different from that of the other clutch, andwherein said control means includes means for selectively renderingeither of the clutches active and the other inactive, thereby to varythe rate of yarn fed to selected needle groups.

7. A tufting machine comprising a needle bar, a plurality of needlescarried thereby, means for reciprocating the needle bar, a plurality offeed rolls adapted respectively to feed yarn to different predeterminedgroups of the needles, means for driving selectively the respective feedrolls at any one of a plurality of predetermined speeds, said drivingmeans including plural clutches for each feed roll, there being aseparate clutch for each different speed, and clutch control meansresponsive to the timed operation of a driven part of the machine forsimultaneously energizing like speed clutches of the feed rolls, and forselectively energizing either speed clutch of any feed roll, thereby tovary the relative driving speed of different feed rolls.

8. In the method of forming patterns with pile loops in a base fabriccomprising simultaneously inserting a plurality of needles carryingthreads through said fabric to a predetermined depth, temporarilyholding the threads at such predetermined depth while withdrawing saidneedles from said fabric to produce a first series of loops alignedtransversely of the line of feed, releasing said first series of loops,furnishing a length of thread to each needle during the reciprocation ofthe needle for use in the formation of a second series of aligned loopsand again simultaneously inserting the needles carrying the threadsthrough said fabric to said predetermined depth along a line spaced fromthe first series of loops, temporarily holding said threads at saidpredetermined depth to form said second series of aligned loops, thestep of furnishing according to a prescribed pattern a lesser length ofthread to at least one of the needles forming the loops in the secondseries of loops than to the other needles forming the loops in saidsecond series, withdrawing the needles from said fabric while holdingthe loops and simultaneously adjusting the length of said 11 loop in thefirstseries of loops corresponding to the loop formed in the secondseries of loops by said one needle by drawing thread from said loop inthe first series in an amount corresponding to the difference in lengthbetween said first mentioned length of thread and said lesser length ofthread, whereby the lengths of the loops in the first series will varyaccording to the length of thread furnished by said loops to thecorresponding loops in the second series, and then releasing the loopsin the second series of loops.

9. In a tufting machine comprising a frame including a top housing and abed plate, a shaft journaled in said top housing, means for impartingrotation to said shaft, a needle bar, a plurality of needles carried bysaid needle bar, means for mounting said needle bar on said top housingfor reciprocation to pass said needles through said bed plate uponreciprocation thereof, means operatively connecting said shaft and saidneedle bar for imparting reciprocation to said needle bar upon rotationof said Shaft, a rock shaft mounted in said bed, a plurality of hooks onsaid rock shaft for cooperating individually in timed relation with eachof said needles to enter and to release loops of thread on said needles,means for feeding a base fabric across said bed plate and past saidneedles, means for feeding upon each stitch to each needle 21' length ofthread that in accordance with a predetermined pattern is variablebetween different ones of said needles and for any one needle isvariable between successive stitches, stationary thread guiding meanssecured on said frame adjacent to the needles for guiding a threadtoward each needle, and means movable with the needle bar for ngagingthe threads between said stationary thread guiding means and theneedles'in each cycle for alternately taking up and letting out constantlengths of thread as the needle bar isr'ecipromted, said last-mentionedmeans'being adapted to deflect the threads transversely of the lengththereof and draw thread from a loop in the work on the upstroke of theneedle bar.

10. In a tuftirig machine in accordance with claim 9 having a secondthread guiding means spaced from said first thread guiding means anddefining therewith substantially straight thread paths, and in whichsaid lastmentioned means comprises a thread deflecting bar carried bysaid needle bar for movement in a path between said thread guiding meansfor engaging said threads upon the upstroke of said needle bar and fordeflecting said threads from saidstraight thread paths with a maximumdeflection of said threads at the top of the needle bar stroke.

References Cited in the file-of this patent UNITED STATES PATENTS876,562 Kleutgen Jan. 14', 1908 1,831,485 Dykeman Nov. 10, 19311,863,049 Herman June 14, 1932 1,909,531 Gladish May 16, 1933 2,040,427Boyce May 12, 1936 2 ,304,902 Elvin et a1 Dec. 15, 1942 2,335,487 Cobbleet a1 Nov. 30, 1943 2,411,268 Hamrick Nov. 19, 1946 2,458,229 VredenburgJ an. 4, 1949 2,853,034 Crawford Sept. 23, 1958 2,876,441 Boyles Mar. 3,1959

